Overvoltage protection component

ABSTRACT

An improved overvoltage protection component is provided. The overvoltage protection component has a first internal electrode contained within a dielectric material. The first internal electrode is electrically connected to a first termination and a second internal electrode contained within the ceramic dielectric material is electrically connected to a second termination.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/505,791 filed Jul. 8, 2011.

BACKGROUND

Overvoltage protection is typically provided by voltage dependent resistors, such as Schottky diodes based on SiC, or varistors, based on ZnO, which work on solid state principles related to grain boundary conduction.

The most popular type of voltage dependent resistors, or varistors, are based on zinc oxide doped with other elements to control the grain boundaries. These devices depend on their non-linear I-V behavior transient voltage surges. However, there are some significant compromises that result from their use. Voltage permanently applied to the varistor must be carefully limited to avoid excessive power dissipation. Since they often have a negative temperature coefficient of resistivity a runaway condition can easily be precipitated. Subjecting varistors to electric fields can change the characteristic and result in an increase in current and power dissipated as heat degrading performance.

There has been an ongoing desire for an overvoltage protection device which does not have the deficiencies of the prior art.

SUMMARY

It is an object of the present invention to provide a component that also functions as an overvoltage protection device.

It is a further object of the present invention to provide an overvoltage protection component that can be readily manufactured by similar methods currently used for multi-layer ceramic capacitors (MLCC).

A particular feature of the invention is that overvoltage protection can be realized that is surface mountable, can be produced in a miniaturized form and is suitable for large scale mass production.

These and other advantages, as will be realized, are provided in an overvoltage protection component. The overvoltage protection component has a first internal electrode contained within a ceramic dielectric material. The first internal electrode is electrically connected to a first termination and a second internal electrode contained within the ceramic dielectric material is electrically connected to a second termination.

A gap is between the first internal electrode and the second electrode. Yet another embodiment is provided in an improved electronic device. The electronic device has a circuit with at least two traces. An overvoltage protection is provide having a first internal electrode contained within a ceramic dielectric material and electrically connected to a first termination. A second internal electrode is contained within the ceramic dielectric material and electrically connected to a second termination. A gap is between the first internal electrode and the second electrode wherein the first termination is in electrical contact with a first trace. A second termination is in electrical contact with a second trace.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 is a schematic cross-sectional view of an embodiment of the invention.

FIG. 2 is a diagrammatic illustration of an embodiment of the invention.

FIG. 3 is an electrical schematic diagram of an embodiment of the invention.

FIG. 4 is a schematic cross-sectional view of an embodiment of the invention.

FIG. 5 is a schematic cross-sectional view of an embodiment of the invention.

FIG. 6 is a schematic cross-sectional view of an embodiment of the invention.

FIG. 7 is a schematic view of an embodiment of the invention.

FIG. 8A is a schematic cross-sectional view of an embodiment of the invention.

FIG. 8B is a schematic cross-sectional view of an embodiment of the invention.

FIG. 8C is a schematic cross-sectional view of an embodiment of the invention.

FIG. 9 is a schematic cross-sectional view of an embodiment of the invention.

FIG. 10 is a schematic cross-sectional view of an embodiment of the invention.

FIG. 10A is an electrical schematic diagram illustrating an embodiment of the invention.

FIG. 11 is a schematic partial cross-sectional view of an embodiment of the invention.

FIG. 12A is a schematic partial cross-sectional view of an embodiment of the invention.

FIG. 12B is a schematic partial cross-sectional view of a standard multi-layer capacitor used as a control.

FIG. 13 is cross-sectional view of an embodiment of the invention.

FIG. 14 is a plot illustrating an advantage of the present invention.

FIG. 15 is a plot illustrating an advantage of the present invention.

FIG. 16 is a plot illustrating an advantage of the present invention.

FIG. 17 is cross-sectional view of an embodiment of the invention.

FIG. 18 is a plot illustrating an advantage of the present invention.

FIG. 19 is a plot illustrating an advantage of the present invention.

FIG. 20 is a plot illustrating an advantage of the present invention.

FIG. 21 is a plot illustrating an advantage of the present invention.

FIG. 22 is a plot illustrating an advantage of the present invention.

FIG. 23 is a plot illustrating an advantage of the present invention.

FIG. 24 is a plot illustrating an advantage of the present invention.

FIG. 25 is a plot illustrating an advantage of the present invention.

FIG. 26 is a plot illustrating an advantage of the present invention.

FIG. 27 is a plot illustrating an advantage of the present invention.

FIG. 28 is a plot illustrating an advantage of the present invention.

FIG. 29 is a plot illustrating an advantage of the present invention.

FIG. 30 is a plot illustrating an advantage of the present invention.

FIG. 31 is cross-sectional view of an embodiment of the invention.

FIG. 32 is a plot illustrating an advantage of the present invention.

FIG. 33 is a plot illustrating an advantage of the present invention.

FIG. 34 is a schematic view illustrating ESD testing of a capacitor.

FIG. 35 is a schematic view illustrating breakdown mechanism of a capacitor.

FIG. 35A is a plot illustrating an advantage of the present invention.

FIG. 35B is a plot illustrating an advantage of the present invention.

DETAILED DESCRIPTION

The present invention is related to overvoltage protection devices. More specifically, the present invention is related to overvoltage protection devices which can be surface mounted, manufactured using conventional manufacturing processes similar to the manufacture of multi-layered ceramic capacitors, and which have superior performance relative to prior art devices.

The invention will be described with reference to the figures which form an integral, non-limiting component of the instant disclosure. Throughout the description similar elements will be numbered accordingly.

The overvoltage protection device of the instant invention uses internal arcing to direct excessive overvoltage to ground and then the overvoltage protection device returns to the insulating state after the overvoltage condition. The overvoltage protection component relies on a different set of principles than the prior art to achieve overvoltage protection which allows for functionality enhanced performance and capability. Specifically, the overvoltage protection can be realized while eliminating loss of power which typically occurs when conventional devices are operated under a permanent bias voltage. Furthermore, rapid dissipation of excessive energy can be achieved.

A particular advantage of the present invention is the ability to provide multi-layer ceramic capacitors (MLCC) that can withstand very high electrostatic discharges (ESD) well beyond the limits of the prior art. These benefits will be apparent from the descriptions in the following sections.

A further advantage of the present invention is that it can also be used to provide a spark gap device that allows the electrical energy to be transmitted at a certain voltage such as in detonation circuits, also referred to as fuses. In these cases the overvoltage protection component offers smaller, readily surface mountable solution compared to other solutions such as gas discharge tubes typically used for this purpose. The technology described in this invention also allows the functionality of a spark gap to be combined with that of the charging capacitor currently employed in detonation circuits. These benefits will be apparent from the descriptions in the following sections.

The problem of protecting circuits from overvoltage is solved by an overvoltage protection device designed to internally arc through controlled gaps between electrodes of opposing polarity within the device. By arranging one or more gaps between opposed electrodes, the electrode metal, electrode shape, shape of the gap, the ceramic dielectric type, and the atmosphere present in the gaps can be arranged such that at a predetermined voltage arcing occurs to ground. Furthermore, by adjusting these parameters the time constant for arcing can be adjusted to match the ramp rate of the voltage transients expected in the circuit.

The capacitance can be adjusted such that if the stored energy at a given voltage is exceeded the excessive energy is dissipated through the internal arcing. Since the internal arcing occurs at a predetermined threshold voltage the circuit can function with a permanently applied voltage without dissipating power. Excess voltage is conducted to ground as electrical energy. Although significant localized heating within the device may occur during the internal arcing process this is a secondary effect of the electrical energy dissipation to ground unlike a varistor that primarily dissipates the energy through heat. Temperature resistant ceramic construction is therefore preferred.

In the overvoltage protection component an arc is formed at a predetermined voltage. The arc may be in air or other atmospheres. The gap in the overvoltage protection capacitor is preferably in a sealed environment with the resulting excess energy conducted away through heat or the opposing electrode to ground. The overvoltage protection component combines the spark gap principle with the materials and manufacturing methods used in MLCC manufacture to increase the scope and application voltages of these devices. Gaps are formed between electrodes on the same plane between electrodes of opposite polarity. The overvoltage protection component of the present invention allows multiple spark gaps to be formed between electrodes of opposed polarity thereby increasing application voltage. Doping of the sacrificial material in the gap can be used to control the surface formed in the gap. Process methods can be used to control and introduce atmospheres other than air. Capacitance layers can be combined with the gaps as required to provide dual functionality.

An embodiment of the invention is illustrated in cross-sectional view in FIG. 1. In FIG. 1, the overvoltage protection component, generally represented at 10, comprises an internal gap, 12, between electrodes, 16, of opposing polarity. The electrodes are in electrical contact with terminals, 14, of opposing polarity. The internal gap has an arc distance, D₁, which must be less than the external distance, D₂, between terminals, 14, of opposed polarity in cases where the surfaces of the dielectric and atmosphere present are the same. The internal gap can be formed during the manufacture of the device using techniques familiar in multi-layer capacitor (MLCC) manufacture. Particularly useful techniques include printing sacrificial material between the electrodes, such as carbon or organic filled ink, that are removed during the co-sintering of the layers. Another technique includes making a hole in the tape between the electrode layers.

The surface condition within the internal gap is important in determining the creepage that corresponds to arcing across the arc distance at the threshold voltage. Different ceramic dielectric materials exhibit different creepage potentials so the threshold voltage at a given arc distance can be controlled. Paraelectric dielectrics, such as C0G class materials, are far less prone to arcing than ferroelectric ceramics such as X7R or X5R class materials. In the case of printing of a sacrificial material doping with inorganic materials can be used to control the surface condition in the internal gap. Additions of ceramic particles may be made to the sacrificial material to retain the gap on processing. Alternatively, gaps may be left in the sacrificial print to allow ceramic to flow into the gap to form ceramic columns within the gap to retain the size and shape of the gap during subsequent processing wherein the column acts as a physical support between ceramic above and below the gap.

Another important factor with respect to controlling the threshold voltage is the electrode material. Metals with different work functions will exhibit different threshold voltages, with respect to arcing, over the same distance. Also the gas present in the internal gap and the energy required for ionization will also affect the threshold voltage.

An advantage of the invention is illustrated in FIG. 2 wherein the function of the overvoltage protection component is illustrated in graphical view. In FIG. 2 voltage (V) as a function of time (T) is illustrated. Above an overvoltage condition (OV) internal arcing dissipates excess voltage to ground thereby returning to a threshold voltage (TV).

An electrical schematic diagram illustrating an advantage provided by the present invention is provided in FIG. 3. If an overvoltage protection capacitor is inserted between an input voltage and ground once the threshold voltage is exceeded internal arcing occurs dissipating the excess energy to ground.

An embodiment of the invention is illustrated in cross-sectional schematic view in FIG. 4. In FIG. 4 multiple layers of electrodes, 16, are provided with internal gaps, 12, in each. The electrodes are between external terminations, 14. This arrangement provides an overvoltage protection component which is capable of handling higher currents, and more energy, than a single layered overvoltage protection component.

An embodiment of the invention is illustrated in cross-sectional schematic view in FIG. 5. In FIG. 5, electrodes, 18, are provided with each electrode having multiple internal gaps, 20, within each electrode. The electrodes are between external terminations, 14. With multiple gaps in an electrode the potential required to achieve internal arcing will be raised thereby increasing the threshold voltage.

An embodiment of the invention is illustrated in cross-sectional schematic view in FIG. 6 wherein dual functionality is provided. In FIG. 6 alternating capacitor electrodes, 22, of opposing polarity with an active dielectric, 24, at least between the capacitor electrodes provides a capacitive couple between the external terminations, 14. Overvoltage protection is provided by at least one electrode, 16, with a gap, 12, therein, or at least one electrode, 18, with multiple gaps, 20, therein. This embodiment achieves more capacitance with the energy stored in the active capacitor layers.

An electrical schematic diagram of an electronic device, 100, is illutstrated in FIG. 7 wherein the device comprises a circuit, 101, with a device as illustrated in FIG. 6. In FIG. 7, a standard MLCC capacitor, C1, is in electrical parallel with an overvoltage protection component (OVP). When used to protect transmission circuitry a high capacitance capacitor is not desirable since this may result in signal distortion.

Gases can be used in the internal gaps to control the threshold voltage wherein the lower the ionization potential of the gas the lower the threshold voltage. It is therefore desirable, in some embodiments, to process overvoltage protection capacitors with a controlled gas atmosphere within the internal gaps. This can be achieved by controlling the process atmosphere during the co-sintering of the device or by forming the internal gap to the outside of the final device. Particularly preferred gases include atmospheric air or an inert gas selected from He, Ne, Ar, Kr or Xe. Nitrogen and hydrogen may also be used and mixtures of these gases can be employed to alter the breakdown and recovery of the device. Paschen's law states that the breakdown characteristics of a gap (V) are a function of the gas pressure (p) and the gap length (d); V=f(pd). For an air atmosphere and gaps of the order of 1 mm: V=30 pd+1.35 kV, where d is the gap length in cm and p is the air pressure in atmospheres. Most gases have a non-linear response with variation in pressure so mixtures are employed to tailor this for a given application. Pure inert gases are only preferred for high voltages. Other factors such as temperature, humidity and the secondary ionization potential can also affect the breakdown voltage. Vapors may also be introduced to the gap to act as replenishers, the best known of these is mercury vapor used extensively in fluorescent tubes but for gas discharge function the introduction of alcohol or halogen vapors can be beneficial since their high electro-negativity and ability to absorb UV light can help dampen the discharge.

An embodiment of the invention is illustrated in schematic cross-sectional side view in FIG. 8A and in schematic cross-sectional top view in FIG. 8B. In FIGS. 8A and 8B the electrodes, 16, between external terminations, 14, have gaps, 12, which are within a channel, 24, wherein the channel is in flow communication beyond the capacitor body. A gas is entered into the channel and a gas tight seal, 22, is placed over the opening of the channel thereby securing the gas within the chamber.

An embodiment of the invention is illustrated in schematic top view in FIG. 8C. In FIG. 8C the gap is between the terminal, 14, and inner electrode, 16. This embodiment avoids the additional process necessary to add gas tight seals. The external termination itself functions to seal the gas within the gap. Suitable termination materials would not flow into the gap since the distance must be controlled to insure arcing at a defined threshold voltage and the termination would have to be applied in the gas atmosphere required. Suitable termination materials include conductive adhesives, TLPS conductive adhesives and thick films that are processed using a pulse thermode or high power, high frequency light to sinter the termination.

In the case of base metal electrodes, such as nickel or copper, reducing atmospheres are used during the co-sintering of the multi-layers and an oxygen annealing stage is typically used to re-oxidize the ceramic oxides thereby replacing any oxygen vacancies formed during the sintering process. By careful selection of the dielectric material and annealing atmosphere the composition of gas within the gap can be controlled.

An embodiment of the invention is illustrated in schematic top cross-section view in FIG. 9. In FIG. 9 at least a portion of the inner electrodes, 26 converge thereby concentration charge at a narrow portion of the closest approach of opposing electrodes at the narrowest portion of the gap, 28. By concentrating the charge at the narrowest portion of the electrode the threshold voltage can be reduced.

An embodiment of the invention is illustrated in schematic top view in FIG. 10. In FIG. 10 a three-terminal overvoltage protection component is illustrated wherein ground electrodes, 29, with associated ground terminations, 30, reside in the gap. The gap may be a gas filled gap. The electrodes, 32, which preferably converge, are electrically connected to external terminations, 34. The three-terminal device is particularly suitable for use between two transmission lines wherein the overvoltage can be directed to ground in either transmission line or in both lines.

The overvoltage protection devices dissipate overvoltage to ground thereby allowing capacitors to achieve higher electrostatic discharge capability. In standard MLCC's if the voltage applied to the capacitor during the electrostatic discharge (ESD) event exceeds the breakdown voltage the component fails. However, by incorporating the overvoltage protection device the voltage applied during the ESD event is dissipated by internal arcing before any damage occurs to the capacitive couple. In the prior art external arcing has been used to try to protect ESD susceptible MLCC's with varying degrees of success because the surface of the part can be exposed to various environmental conditions, contaminants and/or coatings that affect the external arc and therefore the ability to control the arc voltage is thwarted. Internal arcing provides a consistent way to realize high ESD capable capacitors. More particularly the overvoltage protection component provides a way of protecting sensitive capacitors from overvoltage in a small, low capacitance, MLCC which is the type of capacitor most susceptible to failures caused by ESD.

Furthermore the overvoltage protection components (OVP) described in this invention can also provide a spark gap for a detonation circuit, that are also described as fuses. In these cases the overvoltage protection device would be placed between the power source and electronic fuze initiator (EFI) as shown in FIG. 10A. The overvoltage protection device (OVP) replaces other spark gap devices such as gas discharge tubes that are typically take up more volume thus allowing the circuit to be miniaturized. Also per the teachings of this invention by combining three or more terminals with an appropriate capacitance an overvoltage protection device can be designed that combines the functionality of the charging capacitor and a spark gap so allowing for further miniaturization.

The electrodes are not particularly limited herein with any conductor suitable for demonstration of the teachings. Electrodes suitable for use in capacitors are particularly suitable due there wide spread availability and the ability to manufacture overvoltage protection components in a manufacturing facility designed for the manufacture of capacitors, and particularly multi-layered ceramic capacitors. Base metal electrodes are particularly suitable for demonstration of the invention as are precious metal electrodes.

The ceramic material used as a dielectric or as a material in the gap is not particularly limited herein. Materials suitable for use in C0G and X7R capacitors are particularly suitable for use in the demonstration of the present invention due to their wide spread use in the manufacture of MLCC's and the ability to manufacture overvoltage protection components in facilities designed for the manufacture of MLCC's.

It will be recognized to those skilled in the art of MLCC manufacturing that combinations of the aforementioned materials and processes allow for a broad range of different overvoltage protection components to be realized. The application of this technology is described in the following non-limiting examples that describe how an overvoltage protection components can be formed using similar processes to MLCC.

EXAMPLES 1/1A

A base metal electrode (BME) multi layer ceramic capacitor (MLCC) with a X7R temperature coefficient in 1812 case size was constructed so that an air gap existed between two internal electrodes of opposite polarity to incorporate an overvoltage protection component in an MLCC. The ceramic dielectric material was a BaTiO₃ based formulation compatible with the Ni internal electrodes. The length of the unfired, or green, capacitor was approximately 5.33 mm (0.21 inches) and the width was approximately 3.81 mm (0.15 inches).

The unfired, or green, capacitors were assembled using a dry layer build up process typical in the MLCC industry that incorporates screen printed internal electrodes. The electrodes were screen printed in a pattern containing an array of 1200 capacitors that were singulated into individual green capacitors after the build up process. A small drop of resin was dispensed by pneumatic syringe onto several green ceramic tape layers in the area between the opposing electrodes such that it spanned the gap and contacted each electrode. These samples of the overvoltage protection component were labeled Example 1A and compared to the other MLCC manufactured at this time, the control group Example 1. The gap between the opposing electrodes was 0.03 mm (0.012 inches) and the diameter of the resin drop was typically 0.38 mm (0.015 inches). The internal electrode was made such that the width of the electrode was approximately 3.20 mm (0.126 inches) and length was 5.03 mm (0.198 inches). The ends of the electrode were tapered, with the taper starting at approximately 8.13 mm (0.032 inches) from the end of the electrode and tapered down to a width of approximately 2.44 mm (0.096 inches). FIG. 11 contains an illustration of the electrode and the resin drop. The resin was applied to approximately 30% of the printed electrode array. The green capacitors surrounding the area with the resin drops served as a control group. The sacrificial resin was removed during the binder burnout processing described below, leaving an air gap. The resin was a solution of mainly ethyl cellulose and plasticizers dissolved into dihydro terpineol, with a solids content of approximately 5%. The total green tape thickness for each active layer was 40 microns and for each blank ceramic layer was 25 microns. The capacitors contained 28 total internal electrode layers. After stacking 9 blank ceramic layers and 14 electrode layers the stacking process was paused and two blank ceramic layers were inserted into the stack followed by one printed layer containing the resin drop which was positioned such that the gap between the electrodes was in the approximate center of the capacitor. Next three blank ceramic layers were inserted into the capacitor stack followed by the remaining 13 electrode layers and 9 blank ceramic layers. The entire stack was subjected to a lamination pressure cycle sufficient to bond all layers together.

The organic binders were removed from the green capacitors by heating in a controlled atmosphere to 230-280° C. over a period of 40-96 hours. The atmosphere consisted of nitrogen, oxygen, and water vapor with an O₂ concentration of 5-21% and a dewpoint of 30-60° C. After binder burnout, the capacitors were fired at 1280-1320° C. for two hours in a reducing atmosphere of nitrogen, hydrogen, and water vapor with a pO₂ of 10⁻⁸ to 10⁻¹⁰ atmospheres of oxygen and a dewpoint of 25-40° C. Ramp rate up to the peak temperature ranged from 1-5° C. per minute. During cooling from the peak temperature, the capacitors were subjected to a reoxidation process at 750-1050° C. for two to eight hours. The atmosphere during reoxidation consisted of nitrogen, oxygen, and water vapor with a pO₂ of 5-100 PPM O₂ and dewpoint of 30-40° C. The reoxidation process restores oxygen to the dielectric crystal structure to eliminate oxygen vacancies which may have occurred during firing.

After thermal processing the sintered capacitors were subjected to abrasive tumbling to smooth any sharp edges and corners and to fully expose the internal electrodes. After abrasive tumbling a fritted copper termination paste was applied to the ends of the capacitors to establish an electrical connection to the exposed internal electrodes. After the copper paste was dry, the capacitors were passed through a termination sintering furnace utilizing a nitrogen atmosphere with low partial pressure of oxygen and controlled temperature profile to oxidize the binders and sinter the termination. The temperature in the furnace was increased from room temperature to 870° C. at a ramp rate of approximately 20° C./min, followed by a gradual cool down to room temperature.

After termination an electroplated Ni barrier layer ranging in thickness from 1.27 μm (50 μin) to 3.81 μm (150 μin) was applied over the copper termination, followed by an electroplated layer of Sn in thickness ranging from 2.54 μm (100 μin) to 7.52 μm (300 μin).

After thermal processing, the capacitors were examined using a non-destructive C-mode scanning acoustical microscope (CSAM) to indicate the size and location of the internal air gaps. The examination confirmed that the resin was removed during thermal processing and an internal air gap was present in the overvoltage protection component samples (Example 1A). In addition, destructive physical analysis (DPA) was performed to characterize the internal gap. CSAM images of an MLCC with the gap and a control are shown in FIGS. 12A and 12B respectively. A photo of the air gap found during DPA is shown in FIG. 13. CSAM was used to sort the MLCC's with the air gap so as to choose parts with consistent size air gaps.

The selected capacitors with the internal air gap (Example 1A) representing an overvoltage protection component and the control capacitor parts (Example 1) were subjected to a voltage ramp of 300 volts/second up to ultimate voltage breakdown (UVBD) followed by a second voltage ramp to breakdown at the same voltage ramp rate. Voltage breakdown is characterized by a sudden increase in measured current, usually due to breakdown of the dielectric layer but this can also be due to arcing across the surface of the capacitor between the terminals. A second UVBD test was performed to confirm whether the high current measurement during the first UVBD test was due to dielectric breakdown or due to surface arcing.

The expected average UVBD for this capacitor design and material set is 45 to 55 volts/micron. As can be seen in Table 1, the average UVBD for the control group is 1897 volts which is in the expected range. However, the test group has a significantly lower initial UVBD of 526 volts. The initial UVBD distributions are shown in FIG. 14.

The average second UVBD for the control group (1) is 22 volts, indicating that the control group experienced catastrophic dielectric breakdown as a result of the UVBD voltage. The average second UVBD for the test group (1A) is 58 volts. The second UVBD for the test group shows that it retains the ability to take some charge before dissipating the charge through the internal gap. The second UVBD distributions are shown in FIG. 15. DPA examination of the internal construction of the test group after the application of UVBD voltage shows no evidence of dielectric breakdown in the area of the air gap.

The electrical and physical examinations indicate that the MLCC's containing an internal gap dissipated the voltage applied during UVBD testing by arcing internally. However the shift in UVBD for the test group (1A) from 520 volts to <100 volts between the first and second UVBD tests indicates a permanent change in the ability of the MLCC's with this design of internal gap to dissipate voltage. An indication of this change is the change in insulation resistance (IR) after the second UVBD test as shown in Table 1. The decrease in IR for the control group (1) shown in FIG. 16 to ≦10 k Ohms after UVBD testing is consistent with a decrease in the IR observed after dielectric breakdown. The post UVBD IR of the test group (1A) is higher on average than the control group.

TABLE 1 Capacitance, DF, UVD and IR performance for Examples 1-5D (Averages are noted unless stated otherwise.). Initial Cap, Initial IR, Second UVBD, Post UVBD Cap, Post UVBD IR, G nF Initial DF, % G Ohms Initial UVBD, volts volts nF Post UVBD DF, % Ohms Example n = 10 n = 10 n = 10 n = 10 n = 10 n = 10 n = 10 n = 10 1 154 1.0 11.0 1897 22 155 4.7 <0.01 1A 160 1.1 10.5 526 58 160 3.6 <0.01 2 154 1.1 14.1 1832 20 155 4.8 <0.01 2B 160 1.1 14.4 466 97 161 2.2 <0.01 3 7.7 <0.02 2800 1678 271 Shorted Shorted <0.01 3C 7.8 <0.02 3000 1457 986 7.8 <0.02 Range 0-5490 4* 0.23 <0.02 10200 2240 793 0.23 <0.02 4600 4D 0.23 <0.02 9350 1626 1507 0.23 <0.02 8400 5 0.82 0.006 2680 2259 1086 0.82 <0.02 2030 5E 0.82 0.007 3540 1427 1520 0.82 <0.02 3280 *only 8 samples were measured in this example.

EXAMPLES 2/2B

In Examples 2 & 2B a base metal electrode (BME) multi layer ceramic capacitor (MLCC) with X7R class materials in 1812 case size was constructed in the same manner as described in Examples 1 & 1B so that an air gap existed between two internal electrodes of opposite polarity in the case of Example 2B, except that the capacitors contained three layers with a drop of resin. After stacking 9 blank ceramic layers and 14 electrode layers the stacking process was paused and two blank ceramic layers were inserted into the stack followed by three printed layers containing the resin drop which were positioned such that the gap between the electrodes in each layer was in the approximate center of the capacitor. Next three blank ceramic layers were inserted into the capacitor stack followed by the remaining 13 electrode layers and 9 blank ceramic layers. The entire stack was subjected to a lamination pressure cycle sufficient to bond all layers together.

The selected capacitors with the internal air gap and the control parts were subjected to a voltage ramp of 300 volts/second up to voltage breakdown, followed by a second voltage ramp to breakdown at the same voltage ramp rate. The initial UVBD of the control group was again in the expected range at 1832 volts (Table 1.). The second UVBD of the control group appears to be similar to the second UVBD of Example 1, but the test group exhibits a small increase in the average second UVBD, from 58 volts in Example 1A to 97 volts in Example 2B. A small increase in insulation resistance can also be seen in Example 2B after the second UVBD test compared to Example 1A. DPA examination of the internal construction of the test group after the application of UVBD voltage shows no evidence of dielectric breakdown in the area of the air gap and a cross-section is shown in FIG. 17. The distributions of Example 2 & 2B for initial UVBD, Second UVBD and IR after second UVBD are shown in FIGS. 18, 19 and 20 respectively.

EXAMPLES 3 & 3C

In Example 3 & 3C a base metal electrode (BME) multi layer ceramic capacitor (MLCC) with C0G class materials in 1812 case size was constructed in the same manner as Examples 2 & 2B so that an air gap existed between two internal electrodes of opposite polarity in the case of 2B, except that the capacitors were constructed using CaZrO₃ based dielectric material compatible with Ni internal electrodes. The total green tape thickness for each active layer was 17 microns and for each blank ceramic layer was 5.8 microns. The capacitors contained 61 total internal electrode layers. After stacking 40 blank ceramic layers and 29 electrode layers, the stacking process was paused and 3 blank ceramic layers were inserted into the stack followed by three printed layers containing the resin drop which was positioned such that the gap between the electrodes of each layer was in the approximate center of the capacitor. Three blank ceramic layers were then inserted into the capacitor stack followed by the remaining 29 electrode layers and 40 blank ceramic layers. The entire stack was subjected to a lamination pressure sufficient to bond all layers together.

The selected capacitors with the internal air gap and the control parts were subjected to a voltage ramp of 300 volts/second up to voltage breakdown, followed by a second voltage ramp to breakdown at the same voltage ramp rate. The expected average UVBD for this capacitor design and material set is 95 to 105 volts/micron. As can be seen in Table 1, the average UVBD for the control group is 1678 volts which is in the expected range. Initial average UVBD of the test group 3C was slightly lower at 1457 volts and these distributions are shown in FIG. 21.

The second UVBD distributions are shown in FIG. 22. The average second UVBD for the control group was 271 volts, which was higher than that observed for the second UVBD of the X7R capacitors, Example 2, with similar electrode design as shown in Table 1. However, low post test insulation resistance for the control group, shown in Table 1 and FIG. 23, indicates that the capacitors experienced internal dielectric breakdown. The average second UVBD for the test group was 986 volts, which is significantly higher than the control group. The plot in FIG. 23 shows that six of the ten capacitors tested retained a good insulation resistance, >1 G Ohm, and did not suffer internal dielectric breakdown. DPA examination of the internal construction of the test group after the application of UVBD voltage shows no evidence of dielectric breakdown in the area of the air gap.

Ten capacitors from Example 3C were subjected to repeated cycles of UVBD voltage at a voltage ramp rate of 300 volts/second. Three of the capacitors survived 10 cycles of UVBD. The plot in FIG. 24 shows that after three to four cycles the UVBD voltage settled into a range of 300 to 700 volts and maintained acceptable electrical characteristics as shown in Table 2.

TABLE 2 Characteristics of selected samples from Example 3. IR, Chip Cap, nF DF, % Gohm 1 7.8 .013 72 2 7.8 .011 900 3 7.8 .013 4400

EXAMPLES 4 & 4D

In Example 4 & 4D a base metal electrode (BME) multi layer ceramic capacitor (MLCC) with C0G class materials in 0805 case size was constructed in the same manner as Examples 3 & 3C so that an air gap existed between two internal electrodes of opposite polarity in the case of Example 4D except that the length of the green capacitor was approximately 2.36 mm (0.093 inches) and the width was approximately 1.45 mm (0.057 inches).

The green capacitors were assembled using a dry layer build up process typical in the industry that incorporates screen printed internal electrodes. The electrodes were screen printed in a pattern containing an array of 7000 capacitors, and after the build-up process, singulated into individual green capacitors. The internal electrode was made such that the width of the electrode was approximately 1.04 mm (0.041 inches) and length was 2.06 mm (0.081 inches). The ends of the electrode were tapered, with the taper starting at approximately 0.41 mm (0.016 inches) from the end of the electrode and tapered down to a width of approximately 0.53 mm (0.021 inches). The total green tape thickness for each active layer was 29 microns and for each blank ceramic layer was 4.3 microns. The capacitors contained 30 total internal electrode layers. After stacking 38 blank ceramic layers and 14 electrode layers, the stacking process was paused and 10 blank ceramic layers were inserted into the stack followed by three printed layers containing the resin drop which was positioned such that the gap between the electrodes of each layer was in the approximate center of the capacitor. Ten blank ceramic layers were inserted into the capacitor stack followed by the remaining 13 electrode layers and 38 blank ceramic layers. The entire stack was subjected to a lamination pressure cycle sufficient to bond all layers together.

The selected capacitors with the internal air gap and the control parts were subjected to a voltage ramp of 300 volts/second up to voltage breakdown followed by a second voltage ramp to breakdown at the same voltage ramp rate. The expected average UVBD for this capacitor design and material set was 72 to 80 volts/micron. As can be seen in Table 1, the average UVBD for the control group was 2240 volts which is in the expected range. Initial UVBD of the test group was lower at 1626 volts. The initial UVDBD distributions are shown in FIG. 25, the second UVBD distributions in FIG. 26 and the IR associated with these in FIG. 27.

The average second UVBD for the control group was 793 volts which is <40% of the initial UVBD. Notably the control group post test insulation resistance was relatively high, averaging 4600 G Ohms. Internal DPA examination of the control group showed that an internal dielectric breakdown had occurred during UVBD, as shown in FIG. 28, but the failure was not catastrophic and appeared to allow the capacitor to accept some charge before arcing across the gap between opposing electrode layers.

The average second UVBD for the test group was 1507 volts, which is similar to the initial UVBD of 1626 volts. The plot in FIG. 27 shows that all ten capacitors tested retained insulation resistance of >1 G Ohm. DPA examination of the internal construction of the test group after the application of UVBD voltage showed no evidence of dielectric breakdown in the area of the air gap.

Five capacitors from Example 4D were subjected to repeated cycles of UVBD voltage at a voltage ramp rate of 300 volts/second. Four of the capacitors survived 10 cycles of UVBD. The plot in FIG. 28 showed that after five to seven cycles the UVBD voltage settled into a range of 500 to 140.

EXAMPLES 5 & 5E

In Example 5 & 5E a base metal electrode (BME) multi layer ceramic capacitor (MLCC) with C0G class materials in 1206 case size was constructed in the same manner as Example 4 & 4C so that an air gap existed between two internal electrodes of opposite polarity for 5E, except that the length of the green capacitor was approximately 3.53 mm (0.151 inches) and the width was approximately 2.05 mm (0.081 inches).

The green capacitors were assembled using a dry layer build up process typical in the industry that incorporated screen printed internal electrodes. The electrodes were screen printed in a pattern containing an array of 3000 capacitors that after the build-up process were singulated into individual green capacitors. The internal electrode was made such that the width of the electrode was approximately 1.55 mm (0.061 inches) and length was 3.53 mm (0.139 inches). The ends of the electrode were tapered, with the taper starting at approximately 0.81 mm (0.032 inches) from the end of the electrode and tapered down to a width of approximately 0.79 (0.031 inches). The total green tape thickness for each active layer was 30 microns and for each blank ceramic layer was 4.3 microns. The capacitors contained 39 total internal electrode layers. After stacking 45 blank ceramic layers and 18 electrode layers, the stacking process was paused and 12 blank ceramic layers were inserted into the stack followed by three printed layers containing the resin drop which was positioned such that the gap between the electrodes of each layer was in the approximate center of the capacitor. Twelve blank ceramic layers were inserted into the capacitor stack followed by the remaining 18 electrode layers and 45 blank ceramic layers. The entire stack was subjected to a lamination pressure cycle sufficient to bond all layers together.

The selected capacitors with the internal air gap and the control parts were subjected to a voltage ramp of 300 volts/second up to voltage breakdown, followed by a second voltage ramp to breakdown at the same voltage ramp rate. The expected average UVBD for this capacitor design and material set was 72 to 80 volts/micron. As can be seen in Table 1, the average UVBD for the control group was 2259 volts which is in the expected range. Initial UVBD of the test group was lower at 1427 volts. These distributions are shown in FIG. 29.

The average second UVBD for the control group was 1086 volts which is <50% of the initial UVBD, as seen in Table 1 & FIG. 30. Eight of ten capacitors in the control group exhibit relatively high post test insulation resistance, averaging 2034 Gohms, but an examination revealed evidence of dielectric breakdown as shown in FIG. 31 and 2 capacitors had low IR as shown in FIG. 32.

The average second UVBD for the test group was 1520 volts, which is similar to the initial UVBD of 1427 volts and the initial and second UVBD of Example 4D. The plot, in FIG. 33, shows that all ten capacitors tested retained good post test insulation resistance which is little changed from the pre test insulation resistance. DPA examination of the internal construction of the test group after the application of UVBD voltage showed no evidence of dielectric breakdown in the area of the air gap or in the active region of the capacitor.

Electrostatic Discharge ESD

Ceramic capacitors have generally been very robust in withstanding electrostatic discharge voltages and are typically used to shield sensitive components from transient spikes in line voltage. Low capacitance values are preferred in this application to minimize the effects of the capacitor on the circuit. However, low capacitance values typically do not exhibit the highest ESD robustness. This is explained as follows. FIG. 34 shows a schematic that represents the ESD test circuit wherein the source capacitor is 50. An amount of electrical charge from the source capacitor charged to the ESD test voltage is discharged into the test capacitor, 52, when the switch, 54, is closed. Capacitance, dissipation factor and insulation resistance measurements, after the voltage discharge, are measured and compared to initial measures to indicate any degradation in the test capacitor.

In the ideal ESD testing case as charge flows from the source capacitor to the test capacitor, total charge is conserved and the resulting voltage decreases in amount proportional to the total capacitance as described in Equations A, B and C and test examples shown for a source RC network with a 150 pF capacitor and 2 kΩ resistor. This is consistent with the “Human Body Model” testing required for AEC Q200 testing (Ref: ISO10605:2008 & IEC61000-4-2). Q _(initial)=Cap_(source)×Voltage_(initial) Q= ₁₅₀ pF×8 kV=1.2×10⁻⁶ Coulombs   Equation A: Q_(final)=Q_(inigial) 1.2×10⁻⁶ Coulombs=1.2×10⁻⁶ Coulombs   Equation B: Voltage_(final) =Q/(Cap_(source)+Cap_(cut)) V=1.2×10⁻⁶/(150 pF+1000 pF)*10⁻⁶=1043 V   Equation C:

If the final voltage exceeds the ultimate voltage breakdown (UVBD) of the capacitor, the capacitor may suffer catastrophic dielectric breakdown and electrical shorts. As these formulas show, lower cap values must withstand higher voltages to dissipate a given amount of charge from the source capacitor. This relationship limits the ability of circuit designers to downsize to smaller capacitors for this application because smaller capacitors have lower cap values at a given voltage ratings.

If the UVBD of the capacitor is sufficiently high and the terminal to terminal spacing of the capacitor is small enough, the voltage may discharge across the external surface of the capacitor rather than through the capacitor as a dielectric breakdown. An illustration of these two paths is shown in FIG. 35 where 56 indicated discharge across the internal dielectric, which is destructive, and 58 indicates discharge across the external air gap which does not cause destruction. The tendency for a capacitor to arc across the terminals depends on several factors including the shape and position of internal electrodes, the type of dielectric and the environmental conditions. In addition if the circuit containing the capacitor is coated after assembly this can prohibit surface arcing.

Capacitors produced in Example 4 &4D and Example 5 & 5E were subjected to ESD testing and the results are shown in Table 3. The initial test voltage was 16 kilovolts. If an electrical failure was detected after exposure to the test voltage, the test voltage was reduced to 12 kilovolts and a new sample was tested at the lower voltage. If an electrical failure was not detected, the test voltage was increased to 25 kilovolts and the testing continued. It can be seen in Table 3 that the capacitor test designs containing the internal air gap (4D and 5E) can survive higher ESD voltages than the standard capacitor designs (4 and 5) because the internal air, or spark, gap allows the excess voltage to discharge through the capacitor rather than on the exterior surface or by the internal dielectric breakdown mechanism.

TABLE 3 ESD Test Results 220 pF 750 pF Voltage 4D 4 5E 5 12 kV — — — 0/30 16 kV 0/5  0/5  0/5  2/5  25 kV 0/30 1/15 0/30 —

Samples 4D and 5E show no significant difference in capacitance, dissipation factor or insulation resistance after ESD testing at 25 kV. In the literature, IEEE Transactions 2009 “Electrostatic Discharge Analysis of Multi Layer Ceramic Capacitors”, C Rostamzadeh, H. Dadgostar and F. Canavero, p 35-40 following ESD pulses of +/−15 kV some MLCC were shown to undergo permanent degradation as shown by lower impedance at low frequencies after this test compared to before the test. For this reason the impedance of a few MLCC from sample 5E were measured before and after ESD testing at 25 kV and their average impedances are shown below in FIGS. 35A and 35B respectively. There is no difference in impedance after 25 kV ESD testing in sample 5E, so we can conclude there is no degradation of the capacitors.

The invention has been described with reference to the preferred embodiments without limit thereto. One of skill in the art would realize additional improvements and embodiments which are not specifically described but are within the scope of the invention as set forth in the claims appended hereto. 

The invention claimed is:
 1. An overvoltage protection component comprising: a first internal electrode contained within a dielectric material and wherein said first internal electrode is electrically connected to a first termination; a second internal electrode contained within said ceramic dielectric material and electrically connected to a second termination; and a gap between the first internal electrode and said second electrode wherein said gap comprises a material selected from air, nitrogen, hydrogen and an inert gas.
 2. The overvoltage protection component of claim 1 wherein said gap has a closest separation distance which is less than a closest separation distance between said first termination and said second termination.
 3. The overvoltage protection component of claim 1 further comprising a third internal electrode connected to a third termination wherein third internal electrode contacts said gap between said first second internal electrode and said second internal electrode and not in electrical contact with either of said first second internal electrode or said second internal electrode.
 4. The overvoltage protection component of claim 3 further comprising a fourth internal electrode connected to a fourth termination wherein said fourth internal electrode contacts said gap between said first second internal electrode and said second internal electrode and not in electrical contact with any of said first second internal electrode, said second internal electrode or said third internal electrode.
 5. The overvoltage protection component of claim 1 further comprising a multiplicity of third internal electrodes and a multiplicity of fourth internal electrodes wherein each third internal electrode of said multiplicity of third internal electrodes is separated from a fourth internal electrode of said fourth internal electrodes by a second gap.
 6. The overvoltage protection component of claim 5 wherein said third internal electrodes are in electrical contact with said first termination and said fourth internal electrode is in electrical contact with said second termination.
 7. The overvoltage protection component of claim 5 wherein said third internal electrodes are in electrical contact with a third termination and said fourth internal electrode is in electrical contact with a fourth termination.
 8. The overvoltage protection component of claim 1 comprising multiple gaps between said first internal electrode and said second internal electrode.
 9. The overvoltage protection component of claim 1 where at least one of said first inner electrode or said second internal electrode comprises a material selected from a base metal and a precious metal.
 10. The overvoltage protection component of claim 1 where at least one of said first termination or said second termination comprises a material selected from a base metal and a precious metal.
 11. The overvoltage protection component of claim 10 wherein at least one of said first termination or said second termination is plated.
 12. The overvoltage protection component of claim 1 wherein said dielectric comprises barium titanate or calcium zirconate and at least one of said first internal electrode or said second internal electrode comprises a based metal.
 13. The overvoltage protection component of claim 1 wherein said gap extends to a side of said overvoltage protection component.
 14. The overvoltage protection component of claim 13 further comprising a gas tight seal over said gap.
 15. The overvoltage protection component of claim 1 wherein said first internal electrode and said second internal electrode are coplanar.
 16. An electronic device comprising: a circuit comprising at least two traces; an overvoltage protection component comprising: a first internal electrode contained within a dielectric material and wherein said first internal electrode is electrically connected to a first termination; a second internal electrode contained within said ceramic dielectric material and electrically connected to a second termination; and a gap between the first internal electrode and said second electrode wherein said gap comprises a material selected from air, nitrogen, hydrogen and an inert gas; wherein said first termination is in electrical contact with a first trace of said traces; and said second termination is in electrical contact with a second trace of said traces.
 17. The electronic device of claim 16 wherein said first trace is in electrical contact with electric ground.
 18. The electronic device of claim 16 wherein said gap has a closest separation distance which is less than a closest separation distance between said first termination and said second termination.
 19. The electronic device of claim 16 further comprising a multiplicity of third internal electrodes and a multiplicity of fourth internal electrodes wherein each third internal electrode of said multiplicity of third internal electrodes is separated from a fourth internal electrode of said fourth internal electrodes by a second gap.
 20. The electronic device of claim 19 wherein said third internal electrodes are in electrical contact with said first termination and said fourth internal electrode is in electrical contact with said second termination.
 21. The electronic device of claim 19 wherein said third internal electrodes are in electrical contact with a third termination and said fourth internal electrode is in electrical contact with a fourth terminal termination.
 22. The electronic device of claim 16 further comprising multiple gaps between said first internal electrode and said second internal electrode.
 23. The electronic device of claim 16 where at least one of said first inner electrode or said second internal electrode comprises a material selected from a base metal and a precious metal.
 24. The electronic device of claim 16 where at least one of said first termination or said second termination comprises a material selected from a base metal and a precious metal.
 25. The electronic device of claim 24 wherein at least one of said first termination or said second termination is plated.
 26. The electronic device of claim 16 wherein said dielectric comprises barium titanate or calcium zirconate and at least one of said first internal electrode or said second internal electrode comprises a base metal.
 27. The electronic device of claim 16 wherein said gap extends to a side of said overvoltage protection component.
 28. The electronic device of claim 27 further comprising a gas tight seal over said gap.
 29. The electronic device of claim 16 wherein said first internal electrode and said second internal electrode are coplanar.
 30. The electronic device of claim 16, further comprising a third internal electrode connected to a third termination wherein third internal electrode contacts said gap between said first second internal electrode and said second internal electrode and not in electrical contact with either of said first second internal electrode or said second internal electrode; wherein the third termination is connected to a third trace within the circuit.
 31. The electronic device of claim 30 wherein said third trace is in electrical contact with electric ground.
 32. The electronic device of claim 30 further comprising a fourth internal electrode connected to a fourth termination wherein said fourth internal electrode contacts said gap between said first second internal electrode and said second internal electrode and not in electrical contact with any of said first second internal electrode, said second internal electrode or said third internal electrode; wherein the fourth termination is connected to a fourth trace within the circuit.
 33. The electronic device of claim 32 wherein said fourth trace is in electrical contact with electric ground. 